Pile fabric



Aug. 10, 1937. A. M. MULDOON. 2,089,289

PILE FABRIC Filed July 8, 1933 225*: Else's- WFEEEQQQTQHEW mw lg INVENTOR ANTHONY M. MULDOON i V ORNEY Patented Aug. 10, 1937 i UNITED STATES PATENT OFFICE PILE FABRIC Anthony M. Muldoon, Hightstown, N. J.

Application July 8, 1933, Serial No. 679,458

3 Claims. (01. 139-401) This invention relates generally to improvewarp threads, the bottom substantially straight .ments in tufted pile fabrics such as rugs and warp thread of Figure 1 being omitted. carpets. Figure 6 is another modified form similar to the One object is to provide a durable fabric that form in Figure but with the upper substantially 5 shows the same pattern on the back as on the straight warp thread of Figure 1 being omitted. 5

front thereof. 7 My improved fabric includes parallel rows of Another object is to provide a fabric that is tufted piles 9 and is of the three-shot variety, economical to manufacture on standard type comprising intermediate weft threads I0, upper looms. weft threads I I and lower weft threads I2. These '10 A further object is to provide a fabric that is are all double-preferably as shown. The piles 9 10 long wearing. are made of wool yarn and the weft threads are Other objects and advantages of the present made of jute or any other material suitable for invention will be obvious from the description to the fabric desired. The wefts are shown as comfollow taken in connection with the accompanyprising two threads but it will be understood that ing drawing. in its broadest aspect single threads might be 15 In its preferred form the invention contemused- ;plates a rug or the like woven with three shots Extending lengthwise of the fabric is a warp of weft and sets of four warp threads. thread I3 positioned between the upper welt .The weft threads are preferably double and of threads II and intermediate weft threads I0; and

' relatively stiff threads such as jute or the like. extending in the Same direction e w n e 20 The warp threads are of smaller d ofter t intermediate wefts I0 and lower wefts I2 is anrial such as cotton being more flexible than the other Warp thread While these ps d id weft threads. The weft threads are laid in three the wefts they of Course fi add y t0 the planes which may be considered as the bottom febric- 5 or lower plane, the top or upper plane and an It will be understood that in practice a weight intermediate or central plane and the pile tufts is p aced at ea e d o th s a ps l3 a d 14 in are looped around the wefts of the intermediate O d r to ep them as Straight as practicable plane. Two of the warp threads of each set corwhile weaving, y W the ab s 5 5 respond with what are commonly called chain woven the tension of the weft threads bearing or binder warps and are woven below the wefts against e Said w p l and I4 tends to Crimp 30 of the bottom plane and above the wefts of the the Same more 0 essupper plane, one of these chain warps always Interwoven around and between the wefts I0,

passes beneath the central plane tuft holding H and lland the warps Hand l .isap ir of sowefts and the other chain warp always passes called or binder warps and The above the central plane tuft holding wefts so that cham warps are under the lower wefts 35 the tuft'holding or locking wefts are held between 12, and to one slde of and Over the interthe respective chain warps. The other warp medlate wefts and up and over the upper threads correspond with What are commonly wefts II, and then down and under the next termed divider or i s warps which lower wefts l2 and so on throughout the length 40 tend substantially straight through the fabric- 32535522 33 'ggg f fi i gi 40 2:; 2 53 33 35 giggz a gs 2332; :3 1: 333?; of and under the intermediate wefts II] and up and over the u per wefts II and then down and lymg between the central plane wefts and the under the next lower wefts I2 and so on throughupper t I out the length of the fabric. By reason of this 45 Flgqre 1 1S magrammatm bottom plan f of weave, the chain warps I5 and I6 straddle the a Of One form 0f my lmpmved fabncintermediate wefts I0. It will thus be noted that Figure 2 is an enlarged sectional View showing there are two warps I5 and I6 under the lowerthe elements spaced apart before they are beate most wefts n and the same two warps |5 and O draw q e p are over the upper wefts I I. Also that there are 50 Figure 3 1s a view similar to Figure 2 but with t warps, numbered [4 and 1 under the interthe parts closer together. mediate wefts I0 and two warps I3 and I5 over Figure 4 is a sectional view at righ gles to the intermediate wefts I0. There are two warps, the view of Figure 2. I3 and I4, under the upper wefts II. Over the Figure 5 is a modified form with only three lower wefts I2 are the two warps I3 and I4. 55

The pile tufts 9 are woven around the intermediate wefts II] which are supported by the warp threads I 4 and I6 and held down by warps I3 and I5. The chain warps I5 prevent the intermediate wefts II] from slipping directly above the lower wefts I2, and the chain warps I6'prevent the same wefts ID from slipping directly below the upper wefts II. By reason of this construction the bights I1 of the tufts are positioned between the wefts I2 and II. and are exposed at the rear of the fabric, and yet held up substantially free from contact with the floor. The pile tufts are shown held in an upright position by the associated threads.

From the foregoing it will be seen that'the tufts stand straight upward, and that the bights of the tufts are exposed but removed from the lowermost plane of the fabric so that they form no part of the wearing surface of the fabric, thus increasing the life of the fabric.

' The fourwarps I3, I4, I5 and I6 form a se ries of four throughout the fabric and the piles 9 are positioned between the chain warps I5 and I6 of each series. This construction forms a firm and durable fabric of attractive appearance of sufficient flexibility to permit easy handling and yet .not sleazy orlikely to 'curl -up when in use.

stuifer ordividing warps I3 above described have been omitted.

In Figure o, the lower stuffer or dividing warps I4 have been omitted.-

These modifications are cheaper, lighter and morefiexible and have some-of the advantages of the preferred form but they lack the body and a durability of the preferred 'form.

Other changes and modifications in details might be resorted to'withoutdeparting from the spirit ofthe invention.

Infallforms it will be seen that the pile threads or tufts which form the design or pattern are also visible at the back;

Iclaim:

,1. A tufted pile fabric comprising three sets of weft threads, pile tufts looped around one set 'of...weft threads, a single. series. of crimped warp threads dividing one set ofr'said iwefts' from thetother two sets ihtoldifferent ,horizontalfllayers, said latter two' sets of wefts being unseparated horizontallyfrom each other by said single series ofcrimped warp threads, two sets of weft threads being aboveand one set of weft threads being below the crimped warps, one of the layers above the crimped warps comprisingthe wefts supporting the tufts, a second layer above the crimped warps comprising a second set of weftsfand another layer below the crirnp'ed warps comprising the; third set of wefts, and pairs of chain warps in series, one warp thread of each pair passing under the Wefts of the third set below the crimped "Warps,"upwardly and'to one side of said tuft supporting wefts and downwardly over said other In the form illustratedin Figure 5, the upper of the fabric.

set of Wefts above the crimped warps, the other series of each of said pairs passing under said wefts of the third set below the crimped warps, upwardly and to the other side of said tuft supporting wefts and downwardly over said other set of wefts above the crimped warps, said pile tufts being held laterally between the two seriesl of warps comprising the chain warps and below the crimped warps whereby the bights of the) tufts are visible at the back of the fabric.

2. A tufted pile fabric comprising three sets of weft threads, pile tufts looped around one set of weft threads, a, single series of crimped warp threads dividing one set of said weft threads from the other two sets into different horizontal layers, said latter two sets of wefts being unseparated horizontally from each other by said single series of crimped warp threads, one set of weft threads being above and the other two; sets being below the crimped warps, the layer below the crimped warps comprising the weft threads supporting the tufts and a second setofl weft threads and the other layer above the crimped warps comprising the third set of -weft threads, and pairs of chain warps in series, one warp thread of each pair passing under the second set of weft threadsbelow thecrimped warps, upwardly and to one side of said tuft supporting wefts and upwardly and over the other. set of weft threads above the crimped warps, the other series of each of said pairs passing under said second set of weft threads below the crimped warps, upwardly and to the other 'side of said tuft supporting Weft threads and upwardly over said other set of weft threads above the 'crimpedwarps, the pile tufts being grippedzlaterally between adjacent chain warps and being disposed below the crimped warps whereby thebights of the tufts are visible at the rear of the fabric.

3. A tufted pile fabric comprising three sets,

of weft threads, each set being on a different) horizontal plane, pile tufts looped around. one set of weft threads, a single series of crimped divid- 7 ing warp threads interwovenbetween the weft threads of one plane and the weft threads of the. other planes, the weft. threads on the other planes being unseparated horizontally-my; said single series of crimped warp threads, pairs of chain warps in, series, one. warpthreadiof each pair being interwoven below the. weft threadsfa in the lowermost plane, upwardly and toone side warps and below the crimped warps whereby the pile tufts .are held lateral1y by the chain warps} and, the bights of the tufts are visible at the back ANTHONY uscat; 

